Flexible seal with modular spacers

ABSTRACT

An adjustable seal for coupling a plumbing fixture to a waste outlet includes a member, a flexible sleeve, and a modular spacer. The flexible sleeve is operable to be connected to an upper surface of the member. The modular spacer is operable to couple the modular spacer to the member.

TECHNICAL FIELD

The present disclosure relates generally to devices for connecting conduits, such as plumbing fixtures to waste drain conduits, and more particularly to a flexible seal, including a specially configured flexible sleeve, which mounts to a closet flange and also provides a sealed interconnection between a water closet (toilet) and a water waste drain pipe. Related methods for interconnecting conduits are also described.

BACKGROUND

Water closets, also called toilets, are waste disposal devices commonly installed in most bathrooms. These kinds of plumbing appliances generally include a water-storing receptacle called a water tank that is attached to a siphon seat-shaped bowl called a toilet bowl. Periodically, waste is removed from the toilet bowl by flushing, thereby allowing water to drain from the water tank through the toilet bowl and into a waste drainpipe. In order to work, however, the toilet bowl must be connected to the waste drainpipe by fluid carrying conduits. Typically, the toilet bowl will sit flat on a floor and connect with a rigid water closet flange. The water closet flange in turn connects with conduits leading to a waste drainpipe.

Existing toilet flanges often include a conduit portion for passing the waste fluids through the floor (upon which the toilet sits), a number of openings to fasten the flange to the floor, and other openings to attach the toilet bowl to the flange itself. Additionally, there may be an appropriate seat for a toilet seal, which typically may be made either from wax or by a relatively high-density foam or rubber.

Toilets are installed and located in accordance with interior decorating aesthetics of the bathroom. The location of the toilet is determined by the location of the waste drainpipe in the floor, and logically, this will determine the location of the toilet bowl discharge and hence the location of the outlet flange. In addition, toilets are placed on varying heights of a finished floor. However, in making openings through floors and in making the connection between the toilet bowl discharge and the waste drainpipe, there is some likelihood that the toilet bowl opening will be in an awkward or inconvenient place.

As can be appreciated, the aforementioned problems are attributable to varying construction methods and materials. Most professionals who deal with these kinds of problems turn to the use of wax seals and/or modification of the waste drainpipe. When confronted with a difference in floor height between a ground level on which the outlet flange is installed and a finished floor height on which the toilet sits, the professional may be required to install several stacked wax rings to provide a connection between the outlet flange and the toilet bowl discharge. However, these solutions are messy and are not reliable because the seal connection is not strong enough to prevent leakage and associated odors, and oftentimes they can be expensive and inefficient due to delays in the installation process.

Also, conventional closet flanges are made for a specific type of piping, such as cast iron piping, PVC piping, or ABS piping, but not compatible with multiple types of pipings. One reason is due to metal piping having a smaller internal diameter than the ones made from PVC or ABS.

Improved seals for addressing the above-described problems are desired. Related methods for installing improved seals are also desired.

BRIEF SUMMARY

In an embodiment, an adjustable seal for coupling a plumbing fixture to a waste outlet includes a member, a flexible sleeve, and a modular spacer. The flexible sleeve is operable to be connected to an upper surface of the member. The modular spacer is operable to couple the modular spacer to the member.

In another embodiment, a method of manufacturing a seal includes: forming a member; forming a flexible sleeve operable to be connected to an upper surface of the member; and forming at least one modular spacer operable to couple the modular spacer to the member.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made to the following descriptions taken in conjunction with the accompanying drawings.

FIG. 1A is a perspective exploded view of an exemplary seal apparatus with a modular spacer provided as a plurality of parts.

FIG. 1B is a perspective exploded view of an exemplary seal apparatus with a modular spacer provided as a single part.

FIG. 2A is a side cross-sectional view of the exemplary seal apparatus of FIG. 1 in an operative position between an exemplary plumbing discharge outlet and an exemplary waste flange.

FIG. 2B is a side cross-sectional view of an exemplary seal apparatus in an operative position between an exemplary plumbing discharge outlet and a waste drain pipe.

FIG. 2C is a side cross-sectional view of an exemplary seal apparatus in an operative position between an exemplary plumbing discharge outlet and a waste drain pipe.

FIG. 3 is a side cross-sectional view of the exemplary seal apparatus of FIG. 1 in an operative position between an exemplary plumbing discharge outlet and an exemplary waste flange with the plumbing fixture discharge seated against the seal apparatus.

FIG. 4A is a side cross-sectional view of an exemplary seal apparatus in an operative position between an exemplary plumbing discharge outlet and an exemplary waste flange with the plumbing fixture discharge seated against the seal apparatus.

FIG. 4B is a side cross-sectional view of an exemplary seal apparatus in an operative position between an exemplary plumbing discharge outlet and an exemplary waste flange with the plumbing fixture discharge seated against the seal apparatus.

FIG. 5 is a side cross-sectional view an exemplary seal apparatus in an operative position between an exemplary plumbing discharge outlet and an exemplary waste flange.

FIG. 6 is a side cross-sectional view of an exemplary seal apparatus in an operative position between an exemplary plumbing discharge outlet and an exemplary waste flange.

DETAILED DESCRIPTION

Various aspects of a flexible seal apparatus and related methods for installing a flexible seal apparatus according to the present disclosure are described. It is to be understood, however, that the following explanation is merely exemplary in describing the devices and methods of the present disclosure. Accordingly, several modifications, changes and substitutions are contemplated.

FIGS. 1A and 1B illustrate a flexible seal apparatus 10 for connecting between a plumbing fixture discharge 12 and a waste drainpipe outlet 14 or a waste flange 15. The seal apparatus 10 includes a supporting member 16 and a sleeve 18 disposed through an aperture of the supporting member 16. In some embodiments, the sleeve 18 is integrally formed with the supporting member 16 as a single piece, while in other embodiments, the sleeve 18 is removably seated on the supporting member 16. The supporting member 16 may be ring shaped and may be constructed of a substantially rigid material. One or more modular spacers 17 may be coupled to a lower surface of the supporting member 16. As shown in FIG. 1A, the modular spacer 17 may be separated circumferentially into a plurality of parts. As shown in FIG. 1B, the modular spacer may be provided as a single part, which may be ring shaped.

The sleeve 18 includes an upper portion 30, which may be seated in a radial groove 34 defined in an upper surface of the supporting member 16. In some embodiments, the supporting member 16 includes a uniform upper surface with no radial grooves and the upper portion 30 of the sleeve 18 is seated on the substantially planar upper surface of the supporting member 16. The upper portion 30 of the sleeve 18 includes an inwardly-extending radial lip 36, which is sufficiently flexible to deflect downwardly relative to the upper surface of the supporting member 16 as will be described further below. The inwardly-extending radial lip may be provided at an upper surface of the sleeve 18.

The sleeve 18 further includes a lower portion 38 generally defined as the portion of the sleeve 18 extending below the upper surface of the supporting member 16. In one embodiment, the sleeve 18 is made of substantially uniform material, and thus, the lower portion 38 is sufficiently flexible to permit distortion of the lower portion to achieve non-negligible angles of deflection relative to a non-distorted longitudinal axis thereof. In one example, a non-negligible angle of deflection may be ten degrees or more of deflection of one end of the sleeve 18 relative to an opposing end of the sleeve. The sleeve 18 may be formed of various materials to permit non-negligible flexibility. For example, the sleeve 18 may be formed of materials having a hardness ranging from 35 shore A to 90 shore A, or from 35 shore A to 65 shore A, or more specifically about 50 shore A. As can be appreciated, the uniform nature of the sleeve 18 leads to a reduction in manufacturing costs and the likelihood of error during installation. In some embodiments the hardness of the sleeve 18 is less than the hardness of the supporting member 16. Also, the sleeve 18 may be of any suitable length. In one example, the sleeve 18 is 3-4 inches in length.

The sleeve 18 further includes one or more sealing elements 44 extending annularly about the sleeve. In some embodiments, the sealing elements 44 form a portion of the sleeve 18, and therefore, constitute a region of increased diameter relative to other regions of the sleeve. The sealing element 44 may have a maximum diameter at its upper longitudinal end and generally decrease in diameter to its lower longitudinal end distal from the supporting member 16. In this manner, the sealing element 44 provides a tight water seal with a larger longitudinal coverage than other sealing structures. It is contemplated that the sealing elements 44 may take other shapes so long as they seal the interface between the sleeve 18 and a waste drainpipe or waste flange. For example, the sealing elements 44 may be modified to have a substantially uniform diameter, an increasing diameter from the lower longitudinal end to the upper longitudinal end of the sealing elements, or a varying diameter between longitudinal ends of the sealing elements.

Referring to FIG. 2A, the seal apparatus 10 is shown disposed between the plumbing fixture discharge 12 and the waste flange 15. The waste flange 15 is provided as an inner flange disposed on the inside of the waste drainpipe outlet 14. The plumbing fixture discharge 12 may be seated against the sleeve 18 such that an extended portion 42 of the plumbing discharge comes into contact with inwardly-extending lip 36, thereby deflecting the lip downwardly relative to the upper surface 24 of the supporting member 16.

In another embodiment, as shown in FIG. 2B, the seal apparatus 10 may be disposed against the waste drainpipe outlet 14 and the waste flange 15 is provided as an outer flange disposed on an outside of the waste drainpipe 14. In still another embodiment, as shown in FIG. 2C, the seal apparatus 10 may be disposed against the waste drainpipe outlet 14 and no waste flange is needed.

It is to be appreciated that the flexible seal apparatus 10 has additional benefits, such as the ability to deform to fit undersized pipes. The sleeve 18 may have a substantially circular cross section when not subjected to external forces. Such a configuration is desirable to accommodate connection to a circular-shaped waste flange 15 or waste drainpipe 14. As can be appreciated, the sleeve 18 may accommodate connection to a variety of drainpipes of non-standardized schedules and to plastic or cast-iron drainpipes. Also, the sleeve 18 may accommodate connection to waste drainpipes having varying sizes. For example, the sleeve 18 can be implemented in waste drainpipes having 3 inch (7.5 cm) and 4 inch (10 cm) diameters because of the flexibility of the sleeve. Alternatively, the flexible sleeve 18 can be implemented into either 3 inch or 4 inch drainpipes when utilizing an appropriately-sized seal, such as the seal 44.

Referring to FIG. 3, the inward lip 36 may deflect downwardly beyond the upper surface 24 of the supporting member 16 when in contact with the plumbing discharge 12. The lip 36 provides a tight seal that will prevent gas and fluids from leaking from the interconnection between the plumbing discharge 12 and the waste flange 15 and the seal is sufficient to not break even if the toilet becomes backed up. Moreover, the sealing protection provided by the lip 36 eliminates the need for separate additional elements, such as regular wax seals or foam rubber gaskets.

As discussed above, the sealing element 44 provides a tight seal between the sleeve 18 and the drainpipe 14, thereby preventing fluid and gases from traveling back up the sides of the sleeve when installed.

The seal apparatus 10 may be seated against a surface disposed between a plumbing fixture discharge and a waste drainpipe, such as a floor surface. The sleeve 18 is flexible enough to permit installation between offset, misaligned, angled, or otherwise incongruous plumbing fixture discharges and waste drainpipe outlets.

The seal apparatus 10 may be used to connect a plumbing fixture discharge, such as the distal portion of a toilet, to a waste drainpipe, such as a sewage line. In facilitating this connection, the seal apparatus 10 provides a tight seal and reliable connection to prevent any undue leakage or other undesirable consequence of the connection.

Referring back to FIGS. 2 and 3, the waste flange 15 may be installed connecting to a ground slab 50, which may be any type of structural flooring such as a concrete slab or wood decking. The connection may be secured by disposing a plurality of connectors through a plurality of apertures in the waste flange 15. In some embodiments, a finished flooring 52 may be thicker than the waste flange 15 into which the seal apparatus 10 is to be installed. An upper surface of the waste flange 15 may be positioned below the surface of the finished flooring 52 when the waste flange 15 is positioned directly on the ground slab 50. In the illustrated embodiment of FIG. 3, the upper surface of the waste flange 15 is vertically offset from the surface of the finished flooring 52 by an offset distance 54.

An approach to compensate for the offset distance 54 is to install one or more wax rings stacked together or a standard wax ring combined with an extension ring. However, preparing such a wax ring assembly is an inconvenient task for the installer, and more importantly, the addition of the wax ring parts to the installation introduces additional sources of leaks.

The exemplary seal apparatus 10 shown in FIGS. 2 and 3 allows the upper surface 24 of the supporting member 16 to be raised close to or above the surface of the finished flooring 52, which is installed on top of the ground slab 50. The seal apparatus may include at least one modular spacer 17 that couples to the lower surface 26 of the supporting member 16 and raises the seal apparatus 10 so that the upper surface 24 of the supporting member 16 is close to or above the surface of the finished flooring 52. By raising the supporting member 16, the ease of installation may be improved. The desired height of the plurality of modular spacers 17 may be substantially equal to the thickness of the finished flooring 52 when the modular spacer 17 is placed on the ground slab 50 or a height difference between the upper surface of the waste flange 15 and the surface of the finished flooring 52 when the spacer 17 is placed on the waste flange 15.

The modular spacer 17 may be seated directly on the ground slab 50 or the waste flange 15 and disposed beneath the lower surface of the supporting member 16. In an embodiment, the modular spacer 17 may include at least one projection operable to be received in a recessed area defined in the supporting member 16. In another embodiment, the modular spacer 17 may not include an projection, but may be shaped to fit in an recessed area defined in the lower surface of the supporting member 16. In yet another embodiment, the lower surface of the supporting member 16 may simply rest on top of the modular spacer 17 without mechanical couplings.

Due to the flexibility of the seal apparatus 10, it may be connected to many types of piping, such as piping made of cast iron, PVC, or ABS. It is to be appreciated that the use of the disclosed seal apparatus 10 together with the modular spacer of the present application allows for unexpected, synergistic results during the installation of the seal apparatus 10. Government regulations often require water or air tests to ensure the absence of any leakage in the waste drainpipe. Conducting such tests, however, sometimes requires a flange apparatus to be installed over the waste drainpipe and sealed either by an integral sealing element or an external plug. The installation of a conventional flange apparatus may involve cementing or laminating one end of the conventional flange apparatus to the waste drainpipe. As such, when the finished flooring is laid down after the water or air test, the finished flooring is above the upper surface of the conventional flange apparatus because the vertical position of the conventional flange apparatus can no longer be adjusted. In this respect, the seal apparatus 10 allows for the freedom to adjust for height after the finished flooring is laid down after the water or air test. It is to be appreciated that such height adjustments are effected without the use of wax rings, thereby eliminating additional sources of leaks and improving the ease of installation.

Referring to FIG. 4A, in an embodiment, the seal apparatus 10 includes a plurality of modular spacers 17 that are stackable with each other. In FIG. 4, the finished flooring 52 is thicker than the finished flooring 52 shown in FIG. 3. Therefore, the supporting member 16 needs to be raised higher above the ground slab 50. The plurality of modular spacers 17 may be stackable with each other to raise the supporting member 16 above the finish flooring surface 52 for receiving a discharge end of a plumbing fixture.

The desired height of the plurality of the stacked modular spacers 17 in FIG. 4A may be substantially equal to the thickness of the finished flooring 52. If the thickness of the finished flooring 52 is greater than the height of a first modular spacer 17 a, the first modular spacer 17 a may be placed directly on the ground slab 50 or the waste flange 15 and then a second modular spacer 17 b may be placed on top of the first modular spacer 17 a. The second modular spacer 17 b may then engage with the lower surface 26 of the supporting member 16 and raise the upper surface 24 of the supporting member 16 above the surface of the finished flooring 52.

The height of the plurality of stacked modular spacers 17 in FIG. 4A is substantially equal to the thickness of the finished flooring 52 when the modular spacer 17 a is placed on the ground slab 50 or a height difference between the upper surface of the waste flange 15 and the surface of the finished flooring 52 when the spacer 17 a is placed on the waste flange 15.

Referring FIG. 4B, the finished flooring 52 is thinner than the finished flooring 52 shown in FIG. 3. Therefore, the modular spacer 17 is not needed and the supporting member 16 may be placed on the waste flange 15.

Referring to FIG. 5, the seal apparatus 100 is shown disposed between the plumbing fixture discharge 12 and the waste flange 15. The waste flange 15 is shown as an inner flange disposed on the inside of the waste drainpipe outlet 14 without loss of generality to other waste flange and/or waste drain pipe arrangements. When seated against the sleeve 118, the plumbing fixture discharge 12 presses against the sleeve 118 such that an extended portion 42 of the plumbing discharge comes into contact with inward and upwardly extending lip 136, thereby deflecting the lip downwardly relative to the upper surface 124 of the supporting member 116.

The inward and upwardly extending lip 136 may be offset from an upper surface 150 of the sleeve 118 by a height 152. The height 152 may be approximately the same as a thickness of the supporting member 116, though this is merely exemplary and other displacements may also be used.

The inward and upwardly extending lip 136 may form a non-zero or acute angle 154 with a plane orthogonal to a longitudinal axis L of the seal apparatus 100. The angle 154 and a length 156 of the inward and upwardly extending lip 136 may be selected such that an inner surface 160 of the inwardly and upwardly extending lip 136 is at or near a height similar to that of the upper surface 150. The inner surface 160 may be at the same longitudinal height at the upper surface 150 or it may be above or below the upper surface 150.

Referring to FIG. 6, the seal apparatus 200 is shown disposed between the plumbing fixture discharge 12 and the waste flange 15. The waste flange 15 is shown as an inner flange disposed on the inside of the waste drainpipe outlet 14 without loss of generality to other waste flange and/or waste drain pipe arrangements. When seated against the sleeve 218, the plumbing fixture discharge 12 presses against the sleeve 218 such that an extended portion 42 of the plumbing discharge comes into contact with inwardly extending lip 236, thereby deflecting the lip downwardly relative to the upper surface 224 of the supporting member 216.

The inwardly extending lip 236 may be offset from an upper surface 250 of the sleeve 218 by a height 252. The height 252 may be approximately the same as a thickness of the supporting member 216, though this is merely exemplary and other displacements may also be used. The inwardly extending lip 236 may substantially parallel with the upper surface 250. The thickness or number of the modular spacers 17 may be increased to accommodate the height offset 252 and provide a good seal between the extended portion 42 and the inwardly extending lip 236.

In the example shown, the upper surface 250 is above the upper surface 224. However, the upper surface 250 may also be even with or lower than the upper surface 224. Preferably, the upper surface 250 is provided low enough such that the extended portion 42 engages with the inwardly extending lip 236 before the plumbing fixture discharge 12 comes into contact with the upper surface 250 or the supporting member 216.

The breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. Moreover, the above advantages and features are provided in described embodiments, but shall not limit the application of the claims to processes and structures accomplishing any or all of the above advantages.

Additionally, the section headings herein are provided for consistency with the suggestions under 37 CFR 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” the claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Brief Summary” to be considered as a characterization of the invention(s) set forth in the claims found herein. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty claimed in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims associated with this disclosure, and the claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of the specification, but should not be constrained by the headings set forth herein. 

1. An adjustable seal for coupling a plumbing fixture to a waste outlet, comprising: a member; a flexible sleeve operable to be connected to an upper surface of the member; and a modular spacer operable to couple the modular spacer to the member.
 2. The seal according to claim 1, wherein the member includes a recessed area defined in a lower surface of the member, and the modular spacer includes a connecting portion operable to be received in the recessed area of the member.
 3. The seal according to claim 1, wherein the member includes a plurality of recessed areas defined in the lower surface of the member, the plurality of recessed areas being circumferentially spaced from each other.
 4. The seal according to claim 3, further comprising a plurality of modular spacers, each modular spacer including a connecting portion operable to be received in one of recessed areas of the member, thereby coupling the modular spacer to the member.
 5. The seal according to claim 4, wherein a pair of the recessed areas of the member are diametrically opposing each other, and a pair of the plurality of modular spacers are operable to be received in the pair of diametrically opposing recessed areas of the member respectively.
 6. The seal of claim 4, wherein a trio of the recessed areas of the member are evenly spaced from each other about a circumference of the member, and a trio of the plurality of modular spacers are operable to be received in the trio of recessed areas of the member respectively.
 7. The seal according to claim 2, wherein the connecting portion of the modular spacer includes a projection extending from an upper surface of the modular spacer.
 8. The seal according to claim 7, wherein the connecting portion of the modular spacer includes a plurality of projections extending from the upper surface of the modular spacer, the plurality of projections being operable to be received in the recessed area of the member.
 9. The seal according to claim 1, wherein the flexible sleeve is coupled to a waste flange or a waste drain pipe, the waste flange or waste drain pipe is coupled to a ground surface that is below a surface of a finished flooring, the surface of the finished flooring being disposed a distance from the ground surface greater than a distance from an upper surface of the waste flange or waste drain pipe to the ground surface, and the modular spacer has a height and is operable to position the member such that the upper surface of the member is disposed above the surface of the finished flooring.
 10. The seal according to claim 1, wherein the modular spacer includes a cylindrical body and is operable to be disposed around the sleeve.
 11. The seal according to claim 2, wherein the seal includes a plurality of modular spacers, each modular spacer including: an upper surface and a lower surface; a projection in the connecting portion, the projection extending from the upper surface of the respective modular spacer; and a recessed area defined in the lower surface of the respective modular spacer, the projection of a first of the modular spacers is operable to be received in the recessed area of the member, thereby coupling the first modular spacer to the member, and the projection of a second of the modular spacers is operable to be received in the recessed area of the first modular spacer, thereby coupling the second modular spacer to the first modular spacer.
 12. The seal according to claim 11, wherein the plurality of modular spacers each include a plurality of projections extending from the upper surface of the respective modular spacer and a plurality of recessed areas defined in the lower surface of the respective modular spacer, and the plurality of modular spacers each include the same number of recessed areas and projections.
 13. The seal according to claim 11, wherein the plurality of modular spacers each include a plurality of projections extending from the upper surface of the respective modular spacer and a plurality of recessed areas defined in the lower surface of the respective modular spacer, and the plurality of modular spacers each include different numbers of recessed areas and projections.
 14. The seal according to claim 1, wherein the sleeve is unitarily formed of a flexible material and has one or more protrusions along a lower portion of the sleeve.
 15. The seal according to claim 14, wherein the protrusions are formed to couple to a waste flange or waste drain pipe when the lower portion of the sleeve is inserted into the waste flange or waste drain pipe.
 16. The seal according to claim 15, wherein the protrusions provide a substantially water tight seal to the waste flange or waste drain pipe.
 17. The seal according to claim 14, wherein the protrusions are sealing elements disposed about a lower portion of the sleeve, the sealing element having a maximum outside diameter of the lower portion and being sized to directly engage an inside diameter of a waste flange or waste drain pipe.
 18. The seal according to claim 1, wherein the sleeve includes an inward lip extending from an outer, top surface of an upper portion of the sleeve, the lip being sufficiently flexible to deflect downward when engaged by the plumbing fixture discharge.
 19. The seal according to claim 1, wherein the sleeve includes an inward lip extending from a point below an outer top surface of an upper portion of the sleeve, the lip being sufficiently flexible to deflect downward when engaged by the plumbing fixture discharge.
 20. The seal according to claim 19, wherein the lip forms a non-zero angle with a plane that is perpendicular to a longitudinal axis of the sleeve.
 21. The seal according to claim 1, wherein the sleeve is integrally formed with the member.
 22. The seal according to claim 1, wherein the sleeve is removably connected to the member.
 23. The seal according to claim 1, wherein a hardness of the member is greater than a hardness of the sleeve.
 24. A method of manufacturing a seal, comprising: forming a member; forming a flexible sleeve operable to be connected to an upper surface of the member; and forming at least one modular spacer operable to couple the modular spacer to the member.
 25. The method according to claim 24, wherein the member includes a recessed area defined in a lower surface of the member, and the modular space includes a connecting portion operable to be received in the recessed area of the member.
 26. The method according to claim 24, further comprising seating the flexible sleeve on the upper surface of the member.
 27. The method according to claim 24, further comprising coupling the at least one modular spacer to the member.
 28. The method according to claim 24, wherein the forming the member includes forming the member having a plurality of recessed areas defined in the lower surface of the member, and the forming the at least one modular spacer includes forming a plurality of modular spacers in one batch, each modular spacer having an upper surface and a projection extending therefrom, the projection being operable to be received in one of the recessed areas of the member, thereby coupling the modular spacer to the member.
 29. The method according to claim 24, wherein the forming the at least one modular spacer includes forming a plurality of projections extending from the upper surface of the modular spacer, the plurality of projections being operable to be received in the recessed area of the member. 